Process of and apparatus for manufacturing mosaics



(Specimens.)

' H. O. MUELLER. PROCESS OF AND APPARATUS FOR MANUFACTURING MOSAIGS, &c. No. 537,703. Patented Apr. 16, 1895.

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AYE/HAM HERMAN O. MUELLER, OF ZANESVILLE, OHIO.

PROCESS OF AND APPARATUS FOR MANUFACTURING MOSAICS, &c.

SPECIFICATION forming part of Letters Patent No. 537,703, dated April 16, 1895.

Application filed April 12, 1894:- Serial No. 507,216. (Specimens) To all whom it may concern.-

Be it known that I, HERMAN O. MUELLER, a citizen of the United States, residing at Zanesville, Muskingum county, Ohio, have invented new and useful Improvements in Pro cesses of and Apparatus for Manufacturing Mosaics and Penetrating Designs as Applied to Floors, Entablatures, dad, of which the following is a specification.

My invention relates to the art of manufacturing mosaics or of applying colored pigments to the decoration of surfaces, in which, because of wear, desired brilliancy, &c., the design must penetrate some depth, such for example, as earthen entablatures, tiles, glass and metal ware, ceramic articles, floor-cloths, (linoleum, &c.;) its object being to cheapen the cost of production, and also to permit a much wider range of certain classes of ornamental design-work, within moderatelimits of cost, than is practicable with existing methods.

To this end, myinvention consists in aprocess and means of formingthe ornamental surface by the application and distribution of colored pigments through or by means of a system of partitions constituting, what may be termed, a cell-plate, in which a given space is divided by thin partitions into a succession of adjacent spaces relativelyminute-and, in most cases, uniform in size and shape,--covering the area, or a given portion of the area, of the entire design to be produced. The boundary lines of the spaces are independent of the design; but the relative size and arrangement of the cells are such as to allow the distributionof the pigments in a sequence of the cells with sufficient accuracy (considering the size of the design) upon any desired line or over any desired portion of the general surface, thereby rendering it possible to execute any design or figure, with suitable background or contrasting surfaces, with one or more similar cell-plates.

The nature and characteristics of my invention, will more fully appear in the following specification and claims, wherein, for illustrative purposes, I have selected its application to the manufacture of earthen tiles and em tablatures. In such case, the cell-plate is co-extensive with thetile mold in lateral and vertical dimensions, and the distribution of the colored earths to a depth sufficient to form the proper ornamental surface of the tile, is preferably effected by means of suitably prepared cell-screens placed successively over the cell-plate, each used in connection with earth of a given color, to admit earth to the cells selectively, and exclude it from others,- the function being somewhat analogous to that of a stencil. The colored earth's being all in place, the backing earth to form the body of the tile is filled in, the cell-plate is removed and the tile compressed, finished and burned in the usual manner. In the production of larger work, for example, as a vestibule floor of homogeneous design, the process consists, first, in dividing the general surface of the design into spaces coextensive with the tiles to be used providing one or more cellplates for the tile-molds, then providing sets of cell-screens for each color and for each portion of the design included in a given tile space; and,lastly, filling in and completing the tiles, as above indicated, so that the design is reproduced in aggregations of the geometric figure employed in the cell-plate. Thus effects of mosaic or tessellated work, or the similitude of texture of woven fabric, or the ornamental designs may be produced.

The cell-plate, hereinbefore referred to, is a removable partition-blank adapted. to fit thetile mold, composed of an aggregation of vertical partitions so placed and connected as to bound spaces usually of uniform geometric cross areas,-the spaces entire being projections of the area figure, (rectangle, polygon, circle, 850.) The. cross-area of the tile-mold is thus divided into equal divisions. The stencil or screen isa sheet of metal, card board, or the like, cut'awayin part to expose the particular partition'spaces, or aggregation of spaces, devoted to a given color, anda series of such pattern-blanks used successively 1n filling in the earthy pigments, produce the complete design or portion of a design bounded within the space of the tile to be formed.

The function of the cell-plate, it will be understood, is to furnish a temporary lateral support for the color material which, by reason of its vertical depth, or mobility, requires such support until it sets, or, until all the material being in place, each cell-inerement will derive support from those ad olning, upon removal of the cell-plate. In certain of its applications, its further function is to leave vacant between the separate increments of color material the space occupied by the partitions, after the withdrawal of the cellplate, so as to permit an additional color material to be run in as a veining to the whole.

In some cases, the cell-plate may remain in position and become incorporated with the pigment and be thereby cemented to the decorated surface as in Oloissone work.

The apparatus employed in carrying out my invention in its application to tile and kindred work is illustrated in the accompanying drawings, in which- Figure 1 is a perspective view of a tile-mold with the partition or cell-plate and pattern or stencil plate in placein the process of use; Fig. 2, a perspective detail showing construction of the partition or cell-plate; the same being shown inverted; Fig. 3, a partial plan of view a stencil plate; Fig. 4, a detail crosssection of the tile-mold, cell-plate and stencil plate; and Fig. 5represents specimens of tile formed by my process.

Referring now to the drawings, A, designates the base block of a tile-mold; B, the mold proper; (J, the cell plate; and D, a pattern blank employed in sifting-in the colored earth or tile-dust for the tile surface. The base-block and mold are thosecommonly employed in the manufacture of tiles and require no specific description.

As one feature of my invention consists in dividing the entire surface to be treated into minute subdivisions, in order that the ornamental figures and background may be formed by proper aggregation of such spaces devoted to appropriate contrasting color, 1 provide a partition-blank or cell-plate, 0, consisting of an aggregation of vertical partitions, 0, extending the depth of the tile-mold, B, and dividing the entire interior of the mold into small geometric spaces axially projected, such as squares (as shown in Figs. 1 and 2). These partitions are preferably formed of thin sheet metal; and, to secure the structure against injury, the aggregation is, preferably, bounded around its upper portion by an exterior strengthening band, 0', as shown in Fig. 2.

The pattern-blank or stencil plate, D, is a blankof sheet metal,'card board,orother suitable material, having apertures, d, punched or cut in the same, in proper succession and re lation to register with the partition-spaces or an enlarged aperture corresponding with the design intended and covering an aggregation of partition spaces; so that when the cellplate, 0, is in the tile mold, and the stencil plates are adjusted over the same, as shown in Fig. 1, a colored earth or dust may be sifted over the stencil screen and fall through its opening or openings into the appropriate spaces of the cell-plate and be excluded from the covered spaces. In the full figure (3) of the stencil, I have indicated apertures as'squ'ares corresponding with the partition spaces; but they may be circular apertures concentric with the axis of the spaces. Either may be used, or, when the particular color to which the stencil is appropriated, is to occupy a considerable space of adjacent partition spaces, it may be a large opening corresponding with the design and thus substantially following the general outline of the aggregated spaces included in said design.

The mode of procedure is as follows:-The parts being arranged together, as indicated in Figs. 1 and 4:, colored pulverized clay is sifted over the stencil and falls through its openings into the partition spaces,sufficient material being thus applied to give the required depth upon the base block, A. The pattern is then carefully removed (to avoid accidentally throwing dust into the other spaces) and the next stencil substituted; when another installment of pulverized clay, of different color, is applied in like manner. When all special spaces included in the design are thus supplied; the background material is sifted in (no stencil being required) and then the cell-plate is carefully lifted out, and backing material put in to the required depth, or none if the design is to go through the tile, and the pressure-block (not shown) is applied, and the clay compressed in the usualmanner. The tile is then otherwise treated and finished as is customary.

I claim as my invention and desire to secure by Letters Patent of the United States- 1. The improvement in the art of producing mosaics or ornamentally surfaced tiles or entab-latures, consisting in dividing the moldspa'ce by intersecting partition walls of uniform thickness into an aggregation of open cells; distributing colored earths selectively to said cells; removing the partitions and allowing the cell-contents to rest upon the bottom of the mold and acquire lateral support against each other; and finally, by compression of the entire aggregate mass of earth, compressing the tile in the usual manner for the finishing operations; substantially as set forth.

2. The improvement in the art of making mosaics or ornamentally surfaced tiles or entablatures, consisting in temporarily parti tioning the mold into relatively minute cells or spaces irrespective'of the design to be produced; distributing colored earth selectively to such cell-spaces over and by means of suitably perforated patterns or screens; removing the partitions (leaving the cell contents to-acquire lateral support against each other); and then, by compression over the whole mass against the bottom of the mold, fixing the tile for the usual finishing operations; substan* tially as set forth.

3. The improvement-in the art of making mosaics or ornamentally surfaced tiles or entablatures, consisting in temporarily parti* tioning the mold into relatively minute cells or spaces; distributing colored earths selectively'to'all of the cell-spaces in sufficient quantity to give the required depth of surface or nament, and filling in the backing earth; then removing the partitions,allowing the cell contents to acquire lateral support from each other;-and then subjecting the entire mass to pressure against the bottom of the mold; substantially as set forth.

4. In combination with a tile-mold, a removable cell-frame consisting of an aggregation of thin intersecting partitions, dividing the mold-space into adjacent and relatively minute cells of uniform area extending from top to bottom of the mold-space, and arranged in regular order independently of the design to be produced, substantially as set forth.

5. In combination with a tile-mold, a removable partition-blank or cell-plate consisting essentially of a double series of parallel intersectin g cross partitions bounded around their ends through part of their depth by a strip or strengthening band fitting the interior of 2c the mold, substantially as set forth.

6. In combination with a cell plate having an orderly arrangement of cells independent of the design to be produced, and adapted to be removably inserted in a tile-mold, a pattern or series of patterns or stencils following the lines of the design independently of the cell-plate in the tile mold, and admitting the tile earth to cells or aggregations of cells to reproduce the design, substantially as set forth.

In testimony whereof I have hereunto set my hand in the presence of two subscribing witnesses.

HERMAN O. MUELLER.

Witnesses:

KARL LANGENBERT, THEODORE ROESSLER. 

